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1. Disconnect the negative battery cable. 2. Grasp the sides of the electrical caddy (located next the ignition coil) and pull outward to remove. 3. Remove the relay and fuse panels from the electrical caddy. a. Insert a small screwdriver into the slot under each fuse and relay panel. b. Using a screwdriver, disengage the panel from the electrical caddy. 4. Disconnect the main fuse connector from the electrical caddy a. Remove the main fuse from the connector b. Insert small screwdrivers into the slots on each side of the main fuse c. Depress the tabs of the main fuse connector to disengage it from the electrical caddy
Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com 2 EI5075.doc 5. Depress the tab located on the electrical caddy securing the TSM/TSSM. Pull it from the electrical caddy. Disconnect the TSM/TSSM connector. 6. Slide the data link connector towards the front of the motorcycle to disengage it from the electrical caddy. 7. Disconnect the ignition control module connector. 8. Disconnect the ignition coil connector and spark plug cables from the coil. 9. Remove the electrical caddy fasteners (3 total). 10. Remove the wiring from the electrical caddy. 11. Remove the fasteners securing the factory ignition control module from the electrical caddy. 12. Installation of the Digital Ignition Module is the reverse of removal. 2.2 Touring Models 1. Disconnect the negative battery cable. 2. Remove the right saddlebag. 3. Gently pull the side cover from the frame downtubes (no tools required). 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. Remove the two socket screws to detach the ignition control module from the electrical bracket. 6. To install the Digital Ignition Module, install and tighten the socket screws to 50-60 in-lbs . The remainder of installation is the reverse of removal. 2.3 Softail Models 1. Remove the seat. 2. Disconnect the negative battery cable. 3. Remove the two screws to free the ignition control module from the mounting bracket. 4. Depress the external latches and use a rocking motion to remove the electrical connector from the ignition control module. 5. To install the Digital Ignition Module, install and tighten the socket screws to 15-21 in-lbs . The remainder of installation is the reverse of removal

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CHECKING OF SWITCHES Check the switches for the continuity between the terminals to determine correct connection. Read the following for switch inspection. SWITCH CONNECTION AS SHOWN IN MANUAL The manual contains a connection chart as shown left showing the terminal connections of the switches (e.g., main switch, handlebar switch, brake switch, lighting switch, etc.) The extreme left column indicates the switch positions and the top line indicates the colors of leads connected with the terminals in the switch component. “C’&-0″ indicates the terminals between which there is a continuity of electricity; i.e., a cl.osed circuit at the respective switch positions. In this chart: “R and Br” and “L/W and L/R” are continuous with the “ON” switch position. “B and B/W” is continuous with the “OFF” switch position. “B and B/W” is continuous with the “LOCK” switch position. “B and B/W” and “R and L/R” are continuous with the “P” switch position. CHECKING SWITCH FOR TERMINAL CONNECTION Before checking the switch, refer to the connection chart as shown above and check for the correct terminal connection (closed circuit) by the color combination. To explain how to check the switch, the main switch is taken for example in the following

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INSTRUMENT AND CONTROL FUNCTIONS 3-1 3 EAU10460 Main switch/steering lock The main switch/steering lock controls the ignition and lighting systems, and is used to lock the steering. The various positions are described below. EAU10540 ON All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights come on, and the engine can be started. The key cannot be removed. NOTE: The headlight comes on automatically when the engine is started and stays on until the key is turned to “OFF”, even if the engine stalls. EAU10660 OFF All electrical systems are off. The key can be removed. EAU10680 LOCK The steering is locked, and all electrical systems are off. The key can be re- moved. To lock the steering 1. Turn the handlebars all the way to the left. 2. Push the key in from the “OFF” position, and then turn it to “LOCK” while still pushing it. 3. Remove the key. To unlock the steering Push the key in, and then turn it to “OFF” while still pushing it. WARNING EWA10060 Never turn the key to “OFF” or “LOCK” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. Make sure that the vehicle is stopped before turning the key to “OFF” or “LOCK”. 1. Push. 2. Turn. 1. Push. 2. Turn. INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11003 Indicator and warning lights EAU11020 Turn signal indicator light “” This indicator light flashes when the turn signal switch is pushed to the left or right. EAU11060 Neutral indicator light “” This indicator light comes on when the transmission is in the neutral position. EAU11080 High beam indicator light “” This indicator light comes on when the high beam of the headlight is switched on. EAU11250 Oil level warning light “” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the electrical cir- cuit. NOTE: Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a malfunction. This model is also equipped with a self-diagnosis device for the oil level detection circuit. If the oil level detection circuit is defective, the following cycle will be repeated until the malfunction is corrected: The oil level warning light will flash ten times, then go off for 2.5 seconds. If this occurs, have a Yamaha dealer check the vehicle. EAU42740 Fuel level warning light “” This warning light comes on when the fuel level drops below approximately 3.7 L (0.98 US gal) (0.81 Imp.gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, and then go off, have a Yamaha dealer check the electrical circuit. NOTE: The vehicle must be on a level surface and positioned upright, otherwise the fuel level warning light may not come on and go off at the appropriate times. This model is also equipped with a self-diagnosis device for the fuel level detection circuit. If the fue

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Control circuit connections to the motorcycle (normally under the seat or trunk): #1 Brownwireshould be connected to the taillight circuit. #2 Green/Redshouldbe connected to the brake light circuit. #3 LightBlueshould be connected to the left turn signal circuit. #4 Orangeshouldbe connected to the right turn signal circuit. #5 Greenwireshould be connected to frame ground (not to the battery negative post) #6 Yellowwire should be connected to positive 12 volt battery supply. TRAILER ELECTRICAL ISOLATOR WARRANTY -Krissproductsare covered under our standard limited warranty Items returned for inspection must have prior return authorization from the factory. All items must be sent freight prepaid. We are not responsible for any item returned without authorization. Technical assistance is available on the Internet. All items returned for inspection and found to operate properly will be subject to a minimum testing fee. Complete details of our limited warranty maybe found on our internetpages. for defective materials and workmanship. NOTE: Please observe standard good installation procedures by not placing or attaching electrical devices next to plastic decorative outer panels or fairings to prevent damage due to heat. Electricity can produce high temperatures in the event of short circuits. KRISS INDUSTRIESINC. wwwkriss.com . Techinical Support Warranty Assistance Product Information Contact Information KRISS MOTORCYCLE PRODUCTS Installation Procedures Use a test light to identify the correct circuits. If you do not have the proper tools or knowledge to identify the proper wiring we suggest that you seek professional assistance locally. Please note that we are notable to provide telephone or email installation and/or electrical training

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DC SYSTEMS STEP DC1 – REGULATOR/RECTIFIER: PRE-2005 KTM If the stock regulator looks like below (the stock connector will not plug into the Trail Tech regulator/rectifier) then the provided stub connector must be soldered into the bike’s wire harness. For models without a stock battery, mount the reg/rec and plug the stub connector into it. Run the red and black wires directly to the (aftermarket) battery, and the yellow wires to the stator. SEE DC CIRCUIT DIAGRAM ON REVERSE SIDE OF PAGE. MODELS WITHOUT A STOCK BATTERY Move stock light to the DC circuit: divert lighting wire from AC circuit to DC circuit. In stock form, the lights are powered by the AC half of the electrical system. In order to continue to use the stock light, find the yellow wire (runs to stock headlight) shown below (wire bundles are found underneath gas tank) and cut the smaller gauge yellow wire. 1. Connect aftermarket light: Wire the light’s red(+) light lead to the positive(+) battery terminal, and the black(-) light lead to the negative(-) battery terminal. Trail Tech lights should use a 10-20 amp fuse as close to the positive(+) battery terminal as possible.

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Installation 1. Firmly grasp both sides of the existing electrical box cover and pull outward to remove. 2. Install the new cover (1) by aligning the pins (items 2 and 3) with the rubber bushings in the electrical panel and pushing firmly into place

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Definitions: Grounding : The process of making an electrical connection to the general mass of the earth. This is most often accomplished with ground rods, ground mats or some other grounding system. Low resistance grounding is critical to the operation of lightning protection techniques. Bonding : The process of making an electrical connection between the grounding electrode and any equipment, appliance, or metal conductor: pipes, plumbing, flues, etc. Equipment bonding serves to protect people and equipment in the event of an electrical fault. Equipotential Bonding : The process of making an electrical connection between the grounding electrode and any metal conductor: pipes, plumbing, flues, etc., which may be exposed to a lightning strike and can be a conductive path for lightning energy towards or away from the grounding electrode. 2. The National Fuel Gas Code NFPA 54/ANSI Z223 states, “Each above ground portion of a gas piping system upstream from the equipment shutoff valve shall be electrically continuous and bonded to any grounding electrode, as defined by NFPA 70, National Electrical Code ( ANSI/NFPA 70 1999 Edition.) 3. The TracPipe® gas piping system shall be bonded in accordance with the National Fuel Gas Code, NFPA 54/ANSI Z223. The piping system is not to be used as a grounding conductor or electrode for an electrical system. 4. For bonding of the TracPipe® system, a bonding clamp must be attached to the brass AutoFlare®fitting adapter (adjacent to the pipe thread area – see Figure 4-21) or to a black pipe component (pipe or fitting) located in the same electrically continuous gas piping system as the AutoFlare®fitting. The corrugated stain- less steel portion of the gas piping system SHALL NOT be used as the bonding attachment point under any circumstances. Bonding electrode conductor sizing shall be in accordance with Article 250 (Table 250-66) of ANSI/NFPA 70. The bonding is a requirement of the National Electrical Code

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2006 models: communication switch 77173-06 2007 models: communication switch 77173-07 2008 models: communication switch 77173-08 FLHT models will require prior installation of: •Advanced Audio AM/ FM/ CD Radio Kit (76412-06) •AM/ FM Antenna Kit (76325-06 or 76317-06) Unless one has already been fitted as part of another Advanced Audio kit installation: 2006-2007 FLHX models will require the separate purchase of: •fuel tank console (61270-98A), •tank console gasket (71294-89), •a button-head screw (3652), •nut (7964) •clip (10103 and 10120). •tank pod mounting screws (2462) quantity 3 •FLHT trim piece (52447-96) and cb pod trim badge 2008 FLHX models: •fuel tank console (61270-08) •clips (10103 and 10120) NOTE The console screws, fuel door, gasket, mounting bracket will all need to be reused. FLTR models will require the separate purchase of: •a Console Pod Assembly (77136-03), and •three pan-head screws (2462). NOTE See a Harley-Davidson dealer for availability of optional decorative inserts for the Console Pod Assembly. ALL models will require the additional purchase of: •a Non-Ultra Overlay Harness (70169-06), and EITHER : •a Premium Stereo Helmet Headset (77147-98) OR a Hand-Held CB Microphone Kit (76312-98), All of these items are available from a Harley-Davidson Dealer. If two modules are already installed on top of the radio, two Dual-LockTM mounts, (76434-06), will be needed. Models WITHOUT a Tour-Pak installed will require the additional purchase of a Frame Mount CB Antenna Kit (76415- 06). Models WITH a Tour-Pak installed will require the additional purchase of a Tour-Pak Mount CB Antenna Kit (76414-06). All of these items are available from a Harley-Davidson Dealer. The rider’s safety depends upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a) NOTE This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer. Electrical Overload It is possible to overload your motorcycle’s charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle’s charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00211b)

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Main switch EAUO0028 The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU00032 ON All electrical systems are supplied with power, the headlight, meter lighting, taillight and front position lights come on, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed. 1. Push. 2. Release. 3. Turn P (Parking) The meter light, taillight and position lights are on, but all other electrical sys- tems are off. The key can be removed. The key must be pushed in from the “OFF” position to be turned to “P”. ECA00043 Do not use the parking position for an extended length of time, otherwise the battery may discharge. 1. Neutral indicator light ‘NEUTRAL’ 2. Turn signal indicator light ‘TURN’ 3. Fuel level warning light ‘FUEL’ 4. High beam indicator light ‘HIGH BEAM’ 5. Oil level warning light ‘OIL LEVEL’ EAU03034 Indicator and warning lights EAU00062 Neutral indicator light “NEUTRAL” This indicator light comes on when the transmission is in the neutral position. EAU00059 Turn signal indicator light “TURN” This indicator light flashes when the turn signal switch is pushed to the left or right. his warning light comes on when the fuel level drops below approximately 3 L (0.7 Imp gal, 0.8 US gal). When this occurs, refuel as soon as possible. The electrical circuit of the warning light can be checked according to the fol- lowing procedure. 1. Turn the key to “ON”. 2. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. Oil level warning light “OIL LEVEL” This warning light comes on when the engine oil level is low. The electrical circuit of the warning light can be checked according to the following procedure. 1. Turn the key to “ON”. 2. If the warning light does not come on, have a Yamaha dealer check the electrical circuit. NOTE: EAU00064 High beam indicator light “HIGH BEAM” This indicator light comes on when the high beam of the headlight is switched on. Even if the oil level is sufficient, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is not a mal- function

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CAUTIONS IN SERVICING CONNECTOR • * When connecting a connector, be sure to push it in until a click is felt. • * Inspect the connector for corrosion, contamination and breakage in its cover . COUPLER • With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. ( r- 79-14 to 9-16) • * Bend the clamp properly so that the wire harness is clamped securely. • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . i SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . BATTERY • The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. •Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire, first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE ROUTING” section. (C’9-14 to 9-16) ELECTRICAL SYSTEM 8- 3
8-4 ELECTRICAL SYSTEM USING THE MULTI CIRCUIT TESTER •Properly use the multi circuit tester Oand Oprobes. Improper use can cause damage to the motorcycle and tester. • * If the voltage and current values are not known, begin measuring in the highest range . • * When measuring the resistance, make sure that no voltage is applied. If voltage is applied, the tester will be damaged . • * After using the tester, be sure to turn the switch to the OFF position. CAUTION Before using the multi circuit tester, read its instruction manual.